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INDUSTRIAL TRAININGCourse Code: Tex -4036

INDUSTRIAL ATTACHMENTThe Delta Composite Knitting Ind. Ltd.

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PROJECT DESCRIPTIONCHAPTER - 1

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CHAPTER – I

1. Name of the company: The Delta Composite Knitting Ind. Ltd.2. Status : Private Ltd. company

3. Type : 100% Export oriented composite knitdyeing industry

4. Year of establishment : 1998

5. Location : South Zurun, Kashimpur, Gazipur

6. Address :

Factory : South Zurun, Kashimpur, Gazipur

Head Office : Plot No. 389 Lane No:6DOHS, Baridhara, Dhaka

7. Sponsor : Engineer A.K.M. Faruqe Ahammed.

8. Product mix : 100% cotton, 100% polyester, Chief valuecotton, P/C

9. Annual production capacity 2800 tons

10. Project cost 20 crs (Initial), 60 crs (Present)

11. History of the project development1998 – Establishment of the industry

Sample dyeing m/c 2 pcsProduction dyeing m/c 5 pcs

2003 – 2 pcs production dyeing m/c2004 – 10 pcs dyeing m/c

12. DIFFERENT DEPARTMENTS :To run the factory smoothly, there are some department in the factory . They are

given bellow:-KNITTING SECTION: Knitting Inspection

DYEING SECTION Batch section Dye house Dyeing lab.

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Quality control Finishing

MAINTENANCE Electrical Mechanical

ACCOUNTS & COMMERCIAL SECTION

ADMIN SECTION Time section Cleaning Security Store

13. Total area of the industry : 129500 sq. ft.

14. Area of the plant :1st dyeing floor 10800 sq. ft.2nd dyeing floor 27000 sq. ft.

REMARKS:The Delta Composite Knitting Ind. Ltd. is a well established Knit Composite Industry. The area issufficient for the industry. But its drainage system is not very good. There is no system for effluenttreatment.

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MANPOWER MANAGEMENTCHAPTER - 2

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THE DELTA COMPOSITE KNITTING INDUSTRIES LTD.SOUTH JARUN, KASHIMPUR, GAZIPUR

ORGANOGRAMSl.No.

Marketing Commercial A/C &store

ProductionDyeing

ProductionKnit

Quality Utility Administration

01 General Manager02 DGM DGM DGM DGM03 AGM AGM AGM AGM (Factory)04 Manager Manager Manager Manager

(Dyeing)Manager

(Knit)Manager Manager Manager

(Admin)05 Assist

managerAssist

managerCost

AccountantAssistantManager

AssistantManager

AssistantManager

ElectricalEngineer

Administration Officer

06 Sr.Executive

Sr.Executive

Sr.Executive

Sr. Prod.Engineer

Sr. Prod.Officer

QC officer MechanicalEngineer

Sr.Executive

Admin07 Executive Executive Executive Production

EngineerAsst.

ProductionEngineer

AssistantQC Officer

Sub.AssistantEngineer

ExecutiveAdmin

08 Jr.Executive

Jr.Executive

Jr.Executive

Asst. Prod.Officer

Shift In-charge

QC In-charge

Forman Asst. OfficerAdmin

09 Assistant Assistant AccountsAssistant

Lab. Chemist ProductionClark

Sr. QCSupervisor

Supervisor SecurityOfficer

10 Cashier Sr. Lab.Assistant

Sr.Supervisor

QCSupervisor

AssistantSupervisor

ComputerOperator

11 Purchaseofficer

Lab. Assistant Supervisor AssistantQC

Supervisor

Sr. Fitter OfficeAssistant/Time Keeper

12 Sr. Storeofficer

Report Clerk AssistantSupervisor

QC Fitter AssistantTime

Keeper13 Store

officerBatch

InchargeTr.

SupervisorAssistant

QCAssistant

FitterTypist

14 Asst. StoreOfficer

FinishIncharge

Fitter Tr. QC Electrician TelephoneOperator

15 St. StoreKeeper

Froman AssistantFitter

Tr. AssistantQC

AssistantElectrician

DeliverySupervisor

16 StoreKeeper

Sr. Supervisor Operator QC Man BoilerOperator

Peon

17 Asst StoreKeeper

Supervisor AssistantOperator

BoilerAssistant

Driver

18 StoreAssistant

AssistantSupervisor

Tr. Operator GeneratorOperator

Gardener

19 HelperStore

Tr. Supervisor Tr. AssistantOperator

CompressorOperator

Loader

20 Tr. Asst.Supervisor

Helper Asst.Operator

Cleaner

21 Sr. Operator W.T.P.Attendant

Painter

22 Operator Tr. Operator Sweeper23 Asst. Operator Helper24 Tr. Operator25 Assistant Tr.

Operator26 Helper

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MANAGEMENT SYSTEM:

Intercom telephone

Fax

Written letters &

Oral

SHIFT CHANGE: There are two shifts in this industry. So the shifts are changed at every 12 hours

RESPONSIBILITIES OF PRODUCTION OFFICER:

I. To give dyeing program slip.

2. To match production sample with target shade.

3. To collect production sample lot sample matching next production,

4. To observe dyed fabric during finishing running & also after finishing.

5. To identity disputed fabrics & report to P.M/G.M. for necessary actions.

6. To discuss with P.M about overall production if necessary.

7. To sign the store requisition & delivery challan in the absence of P.M.

8. Also to execute overall floor works.

9. To maintain loading'/unloading khata.

10. Any other assignment given by higher authority.

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JOB DESCRIPTION OF PRODUCTION OFFICER:REPORT TO : Sr. Production Officer

JOB SUMMARY: To plan, execute & follows up the production activities &. control thequality production with related activities.

DUTIES & RESPONSIBILITIES: Overall supervision of dyeing, finishing production. Batch preparation & pH I chock. Dyes & chemical requisition issue & check. Write Fabrics loading & unloading time from m/c Program making, sample checking, colour measurement Control the supervisors, operator, ass. operator and helper of

dyeing m/c. And also any other over work as & when required by the management.

JOB DESCRIPTION OF Sr.PRODUCTION OFFICER:

REPORT TO : A.G.M. (production)

JOB SUMMARY: To plan. execute & follows up the production activities & control thequality production with related activities.

DUTIES & RESPONSIBILITIES: Overall supervision of dyeing, finishing production. Checks the sensitive parameters of different machine for smooth

dyeing Checks the different log books of different areas & report to

management Checks out the plan to control the best output from supervisors &

workers. To trained up& motive the subordinates how to improve the quality

production. Control the supervisor, operator, Asstt. Operator & helper of

dyeing. Maintenance of machine & equipment Any other works & when

required by the management

REMARKS:The man power management system of The Delta Composite Knitting Ind. Ltd. is well arranged.

Every officers & stuffs are responsible for their duty. But there are only two textile engineers in theindustry (2 for dyeing). It is not sufficient fluent production. It requires more technical people.

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MACHINE DESCRIPTIONCHAPTER - 3

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MACHINE DESCRIPTION

DYEING FLOORDYEING MACHINES:The Delta composite Knitting Ind. Ltd.. There are 19 dyeing machines. Among them 10 machines arein the first floor and 9 machines are in the second floor. Among first floor, 2 Fongs sample dyeingmachines, 5 Thies ,2 Dilmenler and 1 AYTC production dyeing machine. We worked on the firstfloor. The description and specifications of the machine are given below-

Machine Type 01Name of the machine : Sample Dyeing MachineBrand Name : FongManufacturer : Fong’s National Engineering (SHENZHENE) Co. LTD.Capacity : 25 KgYear of manufacturing: 1997Specification :

No of nozzle: 1Design Pressure: 400

Hydrolic Test Pressure: 650Motor :

Winch motor – 1Pump motor – 1Stirring motor – None

Machine Type 02Name of the machine : Winch Dyeing MachineBrand Name : Thies ( No. of machines :5)Manufacturer : Germany.Capacity : 150,200,400,400,600KgYear of manufacturing: 1995-97Specification :

Maximum operating temp – 1400CMaximum operating pressure – 3.5 bar

Machine Type 03Name of the machine : H.T. Dyeing MachineNo. of machine : 02Brand Name : DILMENLERManufacturer : TurkeyCapacity : 700 KgSpecification :

Maximum operating temp – 1450CMaximum operating pressure – 3 barNo of nozzle – 4Motor

Winch motor – 4Pump motor – 1Stirring motor – 1

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Machine Type 04Name of the machine : ATYC Dyeing MachineNo. of machine : 01Brand Name : ATYCManufacturer : TERRASSACapacity : 900 KgYear of manufacturing: 2002Specification :

Maximum operating temp – 1350CMaximum operating pressure – 3.5 bar (6 bar max.)

Operation process:a. Preparation:

1. Turn on power on main panel2. Open valve for cooling water of main pump3. Check stream, water & air

+ Steam pressure : 5 – 6 kg/cm2 G+ Water pressure : 1.2 – 2 kg/cm2 G+ Air pressure : 5 – 7 kg/cm2 G

4. Adjustment of feeding valve as per production item & capacity

b. Putting fabric into the machine:

1. Select water supply level2. Supply water automatically by pushing ‘turn on’ button and stop by ‘turn off’ button.3. Take up edge of fabric to fabric gate through guide of the reel4. Put edge of fabric to nozzle5. Start main pump and put whole fabric with adjusting feeding by valve upto remaining 2 -3

meters fabric end6. Stop main pump and pull up 2 -3 meters of fabric edge by stick7. Joint both ends of fabric8. Start main pump & reel to circulate whole fabric and adjust torque of speed9. Make sure if fabric circulation is normal, then close the door of the gate, (Check again reel

speed)c. Operation:

1. Close the door2. In-put the pattern on programme controller3. Mix dyeing stuff & chemical in dyeing-mixing tank and pour it with using pouring pump by

adjusting feeding valve, after poring, feeding valve shall be closed4. Switch ‘run’ on programme setting device5. Automatic operation

1) Select the switch of water supply to ‘automatic’ on main panel

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2) Push the button of automatic operation, then automatically operation will go throughheating, holding, cooling, washing as per programming. Put ‘stop’ button whenfinishing buzzer will ring

3) Open the door and take out fabric

Caution:

1. Before operation:(1) Check the power (Voltage/hz) wrong Voltage / Hz will cause to brake motor, meter etc(2) Check air pressure(3) Clean inside of tube before dyeing(4) Set the meter correctly as per dyeing method(5) Check every valves

2. Starting operation:(1) Check closing the door perfectly(2) Set pressure below 1 kg / cm3 by watching pressure meter(3) When temperature will be over more than 800C, do not forget item (1) & (2)(4) Do not start pump when tube is empty(5) Put definitely cooling water before starting operation because pump & reel is made for

cool water3. During operation

(1) Check if meter is working correctly during operation(2) Check if any strange vibration(3) Check if any strange sound of pumping(4) Check if pressure in the tube is too high(5) Check if temperature in the tube meet programming(6) Start pump when feeding steam & cooling water(7) Check if reel is working correct under high temperature & high pressure

4. Nozzle installationSet nozzle base into nozzle-casing and install nozzle by turning it clock wise.After install nozzle, turn it one round by anti-clock wise to make 2 mm gap. The gap on nozzleshall be adjusted by kind of fabric

5. After operation:(1) Before opening the door, check if air pressure of inside the tube is 0 kg/cm2 and

temperature of inside the tube is between 800-900C if the pressure is still remained ortemperature is more than 800C, it is very dangerous to open the door

(2) Temperature inside the tube shall be under 800C for manual draining(3) Turn off the power after operation and close the valve

6. Maintenance:(1) Keep cleaning seal packing of the door and surface to touch the packing to be prevented

from dust and hurting(2) Keep electric portion, pump and control panel not to be wet by water(3) Keep tight valve shaft seal ground packing of each valve by tightening sometime(4) Check valve seat part of air valve & drain valve sometime(5) Keep tight each volt(6) Make often oiling rotating part(7) Inspect mechanical seal according to manual of pump(8) Keep adding grease & oil in pump bearing part according to manual of pump

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(9) Inspect sometime if safety valve is working correctly(10) Inspect sometime if steam trap is working correctly(11) Inspect meters of pressure and temperature

Machineries of the Dyeing Lab:The dyeing lap of The Delta Composite Knitting Ind. Ltd. is not so developed. The description of themachineries of the dyeing lab are given bellow-

Laboratory facilities & equipments: Light box Electric balance Iron Sample dyeing m/c Lab dip m/c GSM tester Washing m/c PH tester Dryer

Light box: Visual assessment of color by reflectance & transmission Mainly used for shade matching Four types of light source are used Sometime it may be more such as TL84, CWD etc Metamerism of the fabric is checked

Brand Name Model Manufacturing countryVITIVIDE CAC-60 U.K.

Types of light source which is used in the m/c is given below-Symbol Full meaning FunctionsUV Ultra violet Used for white color

matchingF Fluorescent light Check the metamerism of

the fabricTL84 Tube light DoL D65 Artificial day light Used for color matching

Crock meter:Feature:

Mainly used for rubbing fastness Rub may be wet and dry

Brand name Mgf. Country Serial no.James H.Heal& Company England S-9011

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Electric balance:Features:

Weight of the fabric and dyes and chemical is measured digitally which give good result inweighting

Used for accurate measurement Maximum weight that can be perfectly measured is 121 gm and minimum weight which

can be measured perfectly is 1.001 gm Accuracy 0.001 gm

Brand Name Company Model CountrySartorius James H. Heal &

Co. LtdBL310 UK

Iron:Feature:

Used for drying the sample Wet sample is placed between the two white fabric and temperature and pressure is given A dial is provided indication the different temperature marked on tits upper surface and

gives accurate temperature for cootn, silk, wool etc. which is adjusted manually.

Sample dyeing Machine:There are three sample dyeing m/c in the laboratory, which features are described below in brief

Solvent – GlycerinModel – HRNo: 3800

M/c type Brand name Company CountryH. T. m/c ROACHES ROACHES EnglandLab. Dip m/c Mathis labomat Werner Mathis. AG Switzerland

Sample dyeing m/c:Feature: Sample can be dyed above 1000C, 1300C or more Glycerin bath is used 18 holders are providing in this machine

Main parts of the machine: Program set panel Glycerin bath Holder Holder carrier

Controlling point: Time Temperature Rotation speed Auto stop

Type of fabric processed: COTTON AND POLYESTER

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GSM Tester:Feature: Used to measure GSM for gray, dyed and finished fabric One GSM tester is in finishing section and another GSM tester is in Knitting Section 100 Cm2 cut sample is weighted by electric balance 3 and given value of in gm.

Multiplied by 100 is the GSM of fabric, Say, 100 cm2 sample weight in 1.9 gm thatmeans its GSM is 180

Washing machine: All the washing condition and parameter can be controlled Model – RS-12MS Temp 1200C Solvent – water + glycerin

m/c no Brand name Company Country1. INDESIT INDESIT Italy

Wash fastness machine:It also used as a dyeing machine. Specification is unknown

Hot air rapid drying oven:Country – TaiwanComponent – Timer, Temperature indication meter

Machinaries of the finishing section:Dewatering machine:

Feature: Used to remove excess water after pretreatment and dyeing Delivered fabric is crease free state Before squeezing ballon is formed with the help of compressed air passing by a nozzle It can control the diameter of fabric and GSM and shrinkage by over feeding mechanism To impart soft finish to the fabric

Brand name Origin Prod.Capacity

AB-CALATOR Sweeden 7 ton/dayFAB-CON American 8 ton/day

Main parts of the machine:- Sqeeze roller (to remove water)- Stretcher (to control width)- Over feeding wheels (to control GSM)- De-twisting device (To delivery the fabric roll in untwisted form)- Folding device (to delivery the fabric in folded form)

Utilities:1. Electricity

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2. Processed air (to form the tube fabric into ballon with a view to remove crease)

Control system:1. Overfeed control2. Pressure3. Speed control4. Width control

Dryer:

M/C no OriginRUCKH GermanySAN-TEX Switzerland

Functions:1. To dry the fabric with help of steam2. To control the shrinkage3. To prepare for next subsequent process4. To dry tubular and open width fabric without tension

Main parts of the machine:1. Heating chamber (2)2. Blower (8)3. Synthetic blanket as a conveyor4. Folder5. Exhaust fan

Heating system:1. Gas fired

Utility:1. Gas (to make fire)2. Electricity (to rum the machine)3. Compressed air (to spread the fire)

Setting according to fabric construction:Fabric type Speed m/min Temperature Over feed speed (%)Single jersey 15 140 20Interlock 20 – 22 140 25 – 30Rib 10 140 15 – 20T/C P/C Viscose 20 – 23 130 40 – 45Lacoste 30 140 40 – 45Collar 20 140 40 – 45Lycra 17 130

Compector m/c:Brand Name Manufacturing Country Production / day

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FERRARO Italy 3 - 6 tons/dayFAB-CON America 3 – 6 tons / day

Control Point :- Water pressure 2.5 lb- Air pressure 4 lb- Steam pressure 6 lb

Function:1. To compact the fabric2. To control the shrinkage3. To maintain proper width and G.S.M

Main parts of the machine:1. Heating chamber2. Blower (8)3. Synthetic blanket as a conveyor,4. Folder5. Exhaust fan

Heating system: Steam

Raising m/c:In which process a layer of fibers lifting from the body of the fabric to achieve soft and lofty effect onthe surface is called raising.

Brand name Country Production / dayXETMA Germany 2-3 tons

Main parts:1. Pin roller2. Counter pole roller3. Blower4. Clean roller

Utility Section:1. Generator2. Boiler3. Air Compressor

1. Generator:An electrical generator is a machine that converts mechanical energy of power into electricalenergy or power.

Brand Name Manufacturer CapacityWAUKESHA 1125 KVACATER PILLAR 390 KVA

Specification:P.F. 0.8Power produced 250 KVA

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Inlet jacket water temp 530COutlet jacket water temp. Oil temperature 720CAir temp. in filter 330COil pressure 4.6 barRaw water pressure 0.5 barGas pressure Inlet air pressure 0.5 bar

Boiler:Brand Name Manufacturer ProductionCleaver brooks U.S.A 100,00 kg/hr

Specification:Feed water temp 600CFeed water hardness 2Steam pressure 500 PSITypes of steam Wet systemSteam temp. 1500CFuel used Natural Gas

Air compressor:An air compressor is a m/c to compress the air and to raise its pressure. The air compressor sucks airfrom the atmosphere, compresses it and delivers the same under in high pressure to a storage vessel.From a storage vessel, it may be conveyed by the pipeline to a place where the supply of compressedair required.

Utility:1. Air2. Mobil3. Electricity

Component:- Motor- Piston- Compressed a- Oil drain plug

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LIST OF THE MACHINERY:

Dyeing machines:

M/CNO M/C TYPE BRAND NAME ORIGIN OF

MACHINEMANUFACT-URING YEAR CAPACITY

01 WINCH THIES GERMANY 2000 150

02 WINCH THIES GERMANY 2000 200

03 WINCH THIES GERMANY 2000 400

04 WINCH THIES GERMANY 2000 400

05 WINCH THIES GERMANY 2000 600

06 H.T. H.P DILMENLER TURKY 2003 700

07 H.T. H.P DILMENLER TURKY 2003 700

08 H.T. H.P ATYC TERRASSA 2002 900

09 SAMPLE FONG SHENZHEN 1997 25

10 SAMPLE FONG SHENZHEN 1997 25

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DYEING LAP

Sl. No. Name of the m/c Brand Name ManufacturingCountry

01 Light box VITIVIDE U.K.02 Crock meter James H.Heal&

CompanyU.K.

03 Electric balance Sartorius U.K.04 Sample dyeing

m/c1. H. T. m/c2. Lab. Dip m/c

ROACHESMathis labomat

EnglandSwitzerland

05 GSM Texter INDESIT Italy

Finishing Floor:

Sl. No. Name of the m/c Brand Name ManufacturingCountry

ProductionCapacity

01 Dewatering m/c AB-CALATOR Sweeden 7 ton/day02 Dewatering m/c FAB-CON American 8 ton/day03 Dryer RUCKH Germany 4.5 tons/day04 Dryer SAN-TEX Switzerland 6 tons / day05 Compactor m/c FERRARO Italy 3-6 tons/day06 Compactor m/c FAB-CON American 3-6 tons/day

Utility Section:Sl. No. Name of the m/c Brand Name Manufacturing

CountryProductionCapacity

01 Generator WAUKESHA 1125 KVA02 Boiler Cleaver brooks U.S.A 390 KVA03 Air Compressor VESPA Taiwan 150 PSI

REMARKS:The average machineries in this factory are more or less same compared to the other knit

dyeing factories but the dyeing machineries are very much different from the other factories.

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RAW MATERIALSCHAPTER - 4

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Raw Materials:In The Delta Composite Knitting €Ind. Ltd., the raw materials used for production are –

1. Grey Fabric2. Dyes3. Chemicals

1. Grey fabrics:Following types of grey fabrics are dyed-

a. Single jerseyb. Single jersey with lycrac. Interlockd. Lacostee. Ribf. Lycra ribg. 1 x 1 rib & othersh. Collar & cuffi. Polyester fabrics

Sources:The required grey fabric is produce in the industry

Chemicals Rate per kg01. Soda ash light 1302. Caustic Soda 3003. Common salt 704. Glauber Salt 905. H2O2 2806. Acetic Acid 1207. Oxalic Acid 4408. Bleaching Powder 2209. Hydrose 4810. Leuphore BMB 52011. Uvtex BHT 30912. Uvtex BHV 28913. Uvtex BAM 31014. Syno White 4BK 34015. Uvtex BFE 91916. Albatex FFC 34417. CHTE nt. K50 24918. Invadine Lun 13619. Feloson NOF 17420. Invadine DA 18021. Invatex CS 7422. Cibacel DBC 10723. Sarbid LDR 15024. Mcropan DPE 126

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25. Cibapon R 15026. Ctobalance NSR 18927. Rucozen RES 11828. Tinofix FRd 15029. Lily XXL powder 4030. Rewan Acp 14531. Cibatex ECO 15032. Invatex CRA 20033. Heptole EMG 11434. Cibafluide C 8935. Biovin 109 18136. Tinozym 44L 56937. Beizym ULBD 34738. Invatex PC 9739. Invatex AC 11740. Catalar BF 324

Dyes Rate per kg01. Solazol Black sp GRI 30002. Reactofix Red ME4BL 26203. Cottofix Red ME4BL 26204. Reactofix Orange ME2RL 29405. Reactofix N.ME2GL 35406. Reactive Yellow H4GL 50007. Reactive Deep Black N 20008. Cottofix Black B 14109. Reactive Blue R(SP) 95010. Remazol Red RR 108011. Remazol Yellow RR 74612. Remazol Blue RR 90813. Remazol Blue BB NEW 228014. Remazol T. Blue G 34415. Remazol B Yellow 3GL 116716. Remazol Red RGD 72517. Cibacron Red FN2BL 148818. Cibacron Red FB 91819. Cibacron Red FN3G 101820. Cibacron Red WB 54221. Cibacron Blue FNR 148822. Cibacron Blue FGFN 154023. Cibacron Navy WB 32324. Drimarin Yellow CL2RL 51025. Drimarin Red CL5B 49426. Drimarin Violet K2RL 160027. Drimarin Navy CLB 743

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28. Drimarin Blue CT2R 164729. Bezaktrive Yellow S3R 51630. Bezaktrive Yellow SLF 97531. Bezaktrive Yellow V GL 132132. Diss Yellow F5GL 40033. Diss Red BF 60034. Diss Blue FRL 110035. Diss Navy 2GL 30036. Diss Black EXNSF 30037. Terasil Black WNS 30038. Terasil Red FB 60039. Terasil Red WFS 60040. Terasil Red W4BS 600

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THE DELTA COMPOSITE KNITTING IND. LTD. IMPORTED YARN PRICING THROUGH L/C:PARTY NAME YARN

CATEGORYRATE $(KG)

RATE (Tk. /KG)

QUANTITY(KGS)

Shameem Spinning 20s/1 CVC 2.70 158 400.00Shameem Spinning 30s/1 CVC 2.80 163 500.00Padma Textile Mills 30s/1 CVC 3.00 175 3628.80Square Textile Mills 24s/1 Comd 2.95 172 850.00Square Textile Mills 12s/1 Kard 2.05 120 500.00Square Textile Mills 10s/1 Kard 1.65 96 1850.00Prime Composite Mills 32s/1 Comd 2.95 172 2550.00Arief Knitspin Ltd 20s/1 Kard 2.58 151 2000.00Arief Knitspin Ltd 26s/1 Kard 2.62 153 2000.00Arief Knitspin Ltd 30s/1 Kard 2.62 153 3250.00Prime Composite Mills 32S/1 Comd 2.95 172 22500.00Arief Knitspin Ltd 24S/1 Comd 3.02 176 10000.00Arief Knitspin Ltd 34S/1 Comd 3.25 190 20000.00Shamsuddin Spinning 24S/1 Comd 3.00 175 6700.00Shamsuddin Spinning 26S/1 Comd 3.00 175 4350.00Arief Knitspin Ltd 20S/1 Comd 3.00 175 1500.00Saiham Textile Millsltd.

30s/1 Kard 2.55 149 661.84

Shamsuddin Spinning 30s/1 Comd 3.05 178 1150.00Shamsuddin Spinning 26s/1 Comd 3.00 175 1800.00Prime Composite mills 20s/1 Kard 2.40 140 1400.00Prime Composite mills 24s/1 Comd 2.85 166 1900.00Prime Composite mills 26s/1 Kard 2.82 165 650.00Prime Composite mills 30s/1 Kard 2.82 165 350.00Hanif Spinning Mills 28s/1 Comd 3.05 178 3800.00Square Textile Mills 26s/1 Comd 2.95 172 500.00Square Textile Mills 24s/1 Kard 2.50 146 500.00Square Textile Mills 10s/1 Kard 1.65 96 600.00Shameem Spinning 30s/1 CVC 2.80 163 1600.00Square Textile Mills 30s/1 Comd 3.00 175 1000.00

REMARKS:The Delta Composite Knitting Ind. Ltd uses best quality raw materials. It produces fabrics

from best quality yarn. They uses the best quality dyes like REMAZOL, REACTRON, REACTIVE ,TERACIL etc. During the time of using dyestuff they give importance upon the quality of dyes thanthe price of the dyes and chemicals.

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PRODUCTION PLANNING,SEQUENCES AND OPERATIONSCHAPTER - 5

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Production parameters:a. pH:

- During H2O2 bleaching pH 9 – 11- During reactive dyeing pH 10.5 – 12- During disperse dyeing pH 4.5 – 5.5

b. Temperature:

- For cotton scouring 900-950C- For cotton cold wash 300 – 400C- For cotton hot wash 700-800C- For cotton acid wash 600-700C- For cotton dyeing 800-900C (For hot brand)

40-600C (For cold brand)- Polyester dyeing: 1000-1300C

c. Time:

- For scouring 60-90 mins- For reactive dyeing 60-90 mins- For disperse dyeing 60-90 mins

d. M:L ratio:

- For reactive dyeing M:L ration maintained beween 1 : 8 to 1 : 10

Description of production process:

Washing for colored fabrics:

- The colored fabrics to be washed is loaded in the machine- Required amount of water is taken- PCLF (detergents) added & washing continued at 800C for 20 mins- Cold washing

Scouring-bleaching:

- Fabric to be scoured is loaded in the machine- Required amount of water is loaded- Washing agent/ detergent is added- Steam pipes are on & scouring agents (i.e. Caustic soda/ Soda ash) added when the temperature

reaches at 500C- When the temperature reaches at 600C then stabilizer is added- Then H2O2 is added

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- Temperature is then raised to 900C and the process is then carried out for 60-90 minsdepending on the requirements

- The liquors are then drained- Then cold wash at 300-400C, hot wash at 700-800C and acid wash at 600-700C is done

Dyeing:

- After acid wash all liquors are drained out- Required amount of water is taken- Then leveling agents, anti-creasing agents, de-foaming agents are added according to the

requirement- Steam pipes are on & after 10-15 mins dyes are added- Salts are added after another 30 mins- Then soda ash after another 30 mins- Then the temperature is raised slowly up to the mark- The process is carried on and samples are taken after every 30-40 mins to match with the target

shade. It continues until shade matching.- If the sample is matched, then the liquors drained out- Then cold wash at 300-400C, hot wash at 700-800C, acid wash at 600-700C is done- Then softener is added at 400C for 20-30 mins- Fixer is applied for deep shade only before adding softener

Re-dyeing:When shade is not matched then fabric is treated again in dyeing machine for shade matching isknown as re-dyeing.Generally, re-dyeing is done if the shade is deeper than the target shade. It may occur when the fabricsabsorb one or two colors more or less. One re-dyeing process is described below.

- Drain the let off solution- Hot wash at 700-800C- Acid wash at 600-700C(600 for light shade & 700 for deep shade).- Soda ash washes at 900-1000C for 60mins to reduce the depth of shade.- Acid wash at 600C.- Addition to required dyestuffs.- Salt addition.- Soda ash addition.- Other operations are same as previous described dyeing operations.

DYEING CURVE:

Auxiliaries Dye SodaTime

60 min600C

Temperature

300C

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Production flow chart:

Production flow chart for 100% cotton↓

Grey fabric loading↓

Scouring & Bleaching at 95oC for 1 hour↓

↓H2O2 killer [invotex PC or gazyme PC]

↓A.Acid

↓Enzyme [pH 4 – 4.5, temp 60oC for 40’-60’]

↓Hot wash

↓Levelling [Ladiquest 1097]

↓Dyeing

SaltColorSoda

↓A. Acid

↓Hot wash [Decol SN, RSK, RFL]

↓Fixing [VNF, ECO]

↓Softener [LCF, Non ionic]

↓Unload

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CVC dyeing sequence:

Perergent + Artioreasomg agent at 800C for 20'↓

cad wash↓

A.Acid [pH 4-4.5]↓

Levelling agent + Antioreasomg agent↓

Buffering agent [jinlab RFL]↓

Color at 130o

50'

↓↓ ↓If OK If not oK↓ ↓Bath Drain temp 1300

↓ ↓½ scouring If OK↓ ↓Cotton dyeing sequence Bath drain

↓½ scouring↓Cotton dyeing sequence

Page no: 31

Dyeing sequence for white:

Scouring + bleaching, 950

↓Blutton´ 50'

↓15'Sample test

↓Water drain

↓Hot (without chem.: at 800C for 20')

↓A.cAcid

↓↓ ↓If OK If not oK↓ ↓Sequester Softener↓ ↓Softner Unload↓Unload

Page no: 32

STANDARD RECIPE OF SCOURING& BLEACHING

SCOURING & BLEACHING:

DEEP SHADE LIGHT SHADE

01. ALBATEX FFC : 0.15 G/L : 0.15 G/L

02. LADIQUEST 1097 : 0.25 G/L : 0.25 G/L

03. CIBAFUUIDE C : 0.50 G/L : 0.50 G/L

04. HOSTAPOL JU : 2.00 G/L : 2.00 G/L

05. CAUSTIC SODA : 2.50 G/L : 2.00 G/L

06. SODA ASH : 2.50 G/L : 2.00 G/L

07. STABILIZER SF. : 0.35 G/L : 0.30 G/L

08. H2O2 (50%) : 3.50 G/L : 3.00 G/L

09. ACETIC ACID : 1.00 G/L : 1.00 G/L

10. INVATEX PC : 0.30 G/L : 0.25 G/L

LEVELLING:

01. CIVAFLUDIE c : 0.50 G/L : 0.50 G/L

02. LADIQUEST 1097 : 0.80 G/L : 0.60 G/L

(FOR LYCRA S/J CIBAFLUIDE C : 0.70 G/L)

LEVELLING: FOR TURQUISE BLUE, R-BLACK, ROYEL COLOUR

01. CIBAFLUIDE C : 0.70 G/L

02. LADIQUEST 1097 : 1.00 G/L

03. E2R : 0.50 G/L

[ FOR WHITE SHADE ]

H2O2 ( 50% ) : ( 4.00 G/L - 7.00 G/L)

Page no: 33

White Dyeing Recipe For (100% Cotton)Buyer Name : Tom Tailor M : L = 1 : 8Order No : Cross line Mtl wt. = 100 kgBatch No : 19100 Water = 800 LiterFabric Type : (1 * 1) Rib Fab dia. = 42 inchG. S. M. : 200 – 210 Colour = White

Serial No Name Dosing (g/l) Quantity Remarks

01 Hostapol JU 0.20 160 gm

02 Cibafluide-C 0.20 160 gm

03 Albatex – FFC 0.20 160 gm

04 Cibafluide – C 0.73 584 gm

05 Hostapol JU 1.20 960 gm

06 Sequester – K 1.00 800 gm

07 Caustec Soada 2.25 1.80 Kg

08 Soda Ash 1.00 800 gm

09 Stabilizer SF .30 240 gm

10 H2O2 4.00 3.20 Kg

12 Acetic Acid 0.60 480 gm

13 Sequester – K 0.40 320 gm

14 Softener (Non - Ionic) 1.50 1.20 Kg

Prepared by : ………………… Checked by : …………………………..Dyeing Incharge : ……………. Production Manager : …………………..

Page no: 34

Flow Diagram of White Dyeing Process of 100% Cotton

950 CH2O2

A

Scouring Chemdosing time 30 min

10 min

6 min

10 min

50 min 25 min

10 min

20 min

Cold wash

800 C 20 min

Levelling Agent+ Anticreasing agent

30 25 20 25

Aceticacid

AcidWash

Softener

Unload

Page no: 35

Colour Dyeing Recipe (100% Cotton)With Reactive Dye

Buyer Name : H & M M : L = 1 : 8Order No : Cross line Mtl wt. = 100 kgBatch No : 19100 Water = 800 LiterFabric Type : S / J Fab dia. = 42 inchG. S. M. : 160 – 170 Colour = Navy

Serial No Name Dosing (g/l) Quantity Remarks01 Hostapol JU 2.00 1.60 kg02 Ladiquest 1097 0.40 320 gm03 Albatex – FFC 0.15 120 gm04 Cibafluide – C 0.50 400 gm05 Stabilizer SF 0.50 400 gm06 Soda Ash 2.50 3.60 kg07 Caustec Soada 3.00 2.40 Kg08 H2O2 4.00 3.20 Kg09 Acetic Acid 1.00 800 gm10 Invatex PC 0.15 120 gm

11 Cibafluider – C 0.50 400 gm12 Ladiquest 1097 0.80 640 gm

13 Reactive S Yellow F3R 0.33 % 330 gm14 Reactive S Red F3B 0.79 % 790 gm15 Reactive Black – 5 4.20 % 4.20 kg

16 Salt 62.00 49.60 kg17 Soda Ash 20.00 16 kg18 RFL 0.80 640 gm19 A. Acid 1.00 800 gm20 Softner (Non Ionic) 1.00 800 gm

Remarks:The Delta Composite Knitting Ind. Ltd. strictly follow the production parameters like the time, temperature, M:L

ratio pH etc. As they do some difficult shade, it takes more time for the production of the batch. Because of the trolleyshortage and generator failure, the production process is sometime hampered. Considering these limitations, the productionofficer and the Sr. Production Officer try their best to reduce the production time.

Page no: 36

QUALITY ASSURANCECHAPTER - 6

Page no: 37

CHAPTER-VI

Q. C. Department

Quality Policy:It is the policy ofThe Delta composite Knitting Ind Ltd to produce quality dyed knit fabrics

that meet or exceed customers expectations & needs. To implement this policy the top management ofUKDL is committed to provide adequate resources in terms of good raw materials and trainedpersonnel & continually improve / upgrade its processes and systems.

Quality Objectives: Overall material/product loss (Level of rejection) for the company during the production

process (in a year) shall not exceed 1.5 % Defects during dyeing & knitting operations to reduced by 10% by the Jan ‘03 Process capability shall be maximized by maximizing the m/c breakdown time. M/c

breakdown time should be reduced to 20 % form its current status/position by the mid 2003. A quality procedure manual in line with the requirement of ISO9001 shall be developed and

implemented by August 2002. To ensure better work environment for the personnel working in the organization.

Machines:

Wash Fastness Tester Light fastness tester Rubbing fastness tester Electronic balance G.S.M. cutter Fabric inspection table Light box Shrinkage (%) meter

Inspection area: Shade match of fabric G.S.M. Fabric diameter Shrinkage (%)

Length wise Width wise

Fiber type Wash fastness Light fastness Rubbing fastness Faults

Dyeing faults Knitting faults

Page no: 38

FAULTS ARE FOUND IN QC DEPERTMENT:Knitting faults:

Hole Slub Thick place Thin place Neps Stripe Missing yarn Contamination

Light Medium Deep

Dyeing faults: Uneven shade Running shade In fastness property

Finishing faults: GSM variation Spirality Shrinkage control

Length wise

Page no: 39

QUALITY ASSURANCE SYSTEM

Quality assurance procedure:The Delta Composite Knitting Industries Ltd. assures the quality of their products in the followingthree steps:

In laboratory

In Dyeing section &

In finishing section

Procedures are described below:

In laboratory: Swatch card from buyer according to their requirement Recipe prediction for sample dyeing Sample dyeing until matching with swatch card If matching is OK, then it is sent to the buyer for approval.

If buyer approves the sample then bulk production.

In dyeing section: After approval form the buyer, sample dyeing is done in dyeing m/c in dyeing shed &

again matched with the approved sample If result is OK. then balk production, During dyeing, samples are taken until accurate shade matching. The interval may be 30-

40 minutes After dyeing sample is collected after softening matching is done Last of all, sample is collected after fixation & matched Then allowed the fabrics to be finished

In finishing section: Correctly dyed, after treated & matched fabrics are allowed for finishing By using a series of finishing machines correct width, softness & appearance are maintained

according to requirements Then sampling is done for several times to test GSM, Shrinkage & fastness properties. Finally fabric is inspected & prepared for delivery

List of Equipments:Machineries & equipment used : Spectrophotometer with software (Datacolor) Colour light box Sample dyeing machine (2) Lab. Dip Iron

Page no: 40

Electric Balance Crock meter Washing m/c GSM Tester PH meter

Quality standard:The Delta Composite Knitting Industries Ltd. follows the quality standard: ISO-9001. 2000

REMARKS:

The Delta Composite Knitting Ind. Ltd. always aware about the quality of the product. The quality ofthe product is always approved by the buyer. They follows the quality standard: ISO 9001: 2000, TheDelta Composite Knitting Ind. Ltd. is well equipped for checking the quality of the product.. Theysent the quality report to the buyer time to time/ batch to batch.

Page no: 41

MAINTENANCECHAPTER - 7

Page no: 42

CHAPTER-VII

MAINTENANCE

Maintenance of Machinery:Maintenance of machinery is very essential mechanical effort for achieving smooth running ofdifferent machines. Maintenance is a process by which equipment is looked after in such a waythat trouble free. Services and increased machine life can be ensured and specific product qualityrequired by the customers is sustained. On time maintenance increase m/c lifetime & ensurestrouble free services.

The Delta composite Knitting Ind. Ltd . 2 types of maintenance are done:1. Break down maintenance2. Routine maintenance

1. Break down Maintenance: Break down maintenance is done instantly when problemarises in machine. In this case, repairs are made after the equipment is out of order and it cannotperform its normal functions.

2. Routine Maintenance: After a particular little the machines are cleaned &reordered, that is routine or schedule maintenance. PPC does it once in a month.Schedule maintenance varies, time in time & also depends on situation according totypes of machines, because maintenance is directly related to production.

Most of the time, all the screws, nuts, bolts & levers are checked, lubrication is also done. Workersinform about the problem areas of the machines. Depending on their information. maintenanceis done, Maintainers analyses the machine records & take steps according to requirements.

Maintenance

Routine Maintenance Break Down Maintenance

Mechanical Maintenance Electrical Maintenance Mechanical Maintenance Electrical Maintenance

Page no: 43

Maintenance procedure:

During maintenance procedure following points should be checked.

Checklist of different parts:

Maintenance: MechanicalMachine: Dyeing Machines

Sl. No. Item need to be checked & Serviced

1 Crease the winch bearing.

2 Complete cleaning of machine

3 Cleaning of drain valves, replace seals if required

4 Check air supply filter, regulators, and auto drain seals

5 Clean filters element and blow out

6 Greasing of Unloading Roller Bearings.

7 Checking of oil level and bolts of Unloading Roller Gearbox.

8 Checking of unloading roller coupling and packing.

9 Checking and cleaning (if required) of Min Vessel Level Indicator

10 Check the oil level of pump bearing and refill if required.

11 Check the function of heat and cool modulating valves

12 Check all belts and belt tension

13 Check all door seals

Maintenance: MechanicalMachine: Lab dyeing m/c.

Sl. No. Item need to be checked & Serviced1 Check rotating main shaft bearing.

2 Check cooling water inlet and outlet nose and nose clips.

3 Check cooling fans

4 Check driving bells and pulleys.

Page no: 44

Maintenance: MechanicalMachine: Lab dyeing m/c.

Sl. No. Items need to be checked & Serviced1 Check & clean fluff and dirt at all motor fan covers2 Check all motors terminals3 Check min panels (by using compressed air)4 Check panel cooling fan & clean it filter5 Clean main pump inverter and its cooling fan6 Check all circuit breaker, magnetic contractors and relays7 Check current setting of all circuit breaker & motor over loads.8 Visual checking of all power & control cables9 Check DC drive of reel motors10 Check all pressure switches11 Check calibration of main vessel & all additional tank12 Check all pneumatic solenoids13 Check calibration of heating/cooling. Modulating value14 Check setting of tangle sensor.15 Check setting & operation of lid safety switches16 Check all emergency Switches17 Check all indicating lamps18 Check all on/off switches19 Check all signal isolators20 Check key pad & display of controller21 Check proximity switches

The following tasks are generally done during maintenance:

Inspections & check ups Lubrications Planning & scheduling Record analysis Training of the maintenance crew Collection or purchase of spares

Page no: 45

MAINTENANCE WORK TO THE DIFFERENT MACHINES:

BOILER MAINTENANCE SCHEDULE:Daily: Check gas pressure Maintain log sheet Chemical dosing

Weekly: Check all steam line Fire quality of boiler

Monthly: Check all steam line Fire quality of boiler Gas consumption report Burner clean

Quarterly: Burner clean Economizer clean Feed tank clean Chemical tank clean Sight glass clean

Half yearly: Burner clean Feed tank clean Chemical tank clean Economizer clean Replace gasket Replace valve Check gas line & filter & pressure

Yearly: Overhauling of boiler Chemical cleaning of boiler Safety valve test Economizer clean Feed tank clean Chemical tank clean Burner clean Check safety valve setting Replace valve & gasket Boiler inspection by authority

Page no: 46

Dyeing m/c maintenance ScheduleDaily: Check belt tension Check steam or water system & air supply Check chemical pump Machine clean

Weekly: Bearing & belt check Check leakage of air, steam & Water line Greasing bearing points Add gland packing at pump

Monthly: Greasing bearing points Replace bearing points (if required) Gaskrt check Clean steam trap Lubricating all chemical pump

Quarterly: Replace belts Repairing of pulley, shaft & bearing housing Painting m/c & pipe line Clean steam trap Replace seals (if leakage) Change gasket of steam of water lines

Half yearly: Replace belts Repairing pulley, shaft & bearing housing Painting m/c, pipe line Replace seals Machine body repairing

Half yearly: Replace belts Repairing pulley, shaft & bearing housing Painting m/c, pipe line Replace seals Machine body repairing

Yearly: Machine overhauling

Page no: 47

Hydro extractor Maintenance

Daily: Machine clean Belt checking

Weekly: M/c clean Belt clean Greasing & lubricating of all points

Monthly: M/c clean Check gear oil quality

Quaterly: Change of gear oil Belt change

Half yearly: Change of gear oil Belt change (if required)

Yearly: Machine overhauling

Page no: 48

TENSIONLESS DRYER MAINTENANCE

Daily: Check belt tension Check steam supply & air system Machine clean

Weekly: Check fabric drying quality Greasing bearing points Clean airfilter & regulator

Monthly: Clean radiator & m/c cabinet Greasing bearing points Clean air filter and regulator

Quarterly: Replace belt Replace gear oil Duct clean

Half yearly: Check roller condition Greasing & lubricating all points

Yearly: Machine overhauling

Page no: 49

TUMBLER DRYER MAINTENANCE:Daily: Check belt Steam leakage area M/c clean

Weekly: Heat exchange clean Greasing & lubricating of all points Belt check M/c clean

Monthly: Filter clean Steam trap clean

Quarterly: Replace belt Replace gear oil Duct clean Gasket & valve change

Half yearly: Gasket & valve change

Yearly: Machine overhauling

Page no: 50

SOFT SET M/C MAINTENANCE:

Daily: Check belt tension Check Steam supply & air system M/c clean

Weekly: Check fabric quality Greasing bearing points

Monthly: Greasing bearing points Clean air filter & regulator Clean steam trap

Quarterly: Replace belts Replace gear oil Painting m/c & pipeline of the total system Replace seals

Half yearly: Check roller condition Greasing & lubricating of all points Check bearing condition

Yearly: Machine overhauling

Page no: 51

Maintenance tools/equipments & their functions:

Maintenance tools/equipments Functions

1. Adjustable wrench Used for setting nut & bolts

2. Pipe Spanner For pipe fitting

3.Spanner Fixed Spanner for nut & bolts fitting

4.Socket spanner Handle system for nut & bolt fitting

5. hammer To apply load where required

6. Screw driver To release any screw

7. Punch Used to fit any worn out shaft

8. Lock opener To open the clip of bearing

9. Hack saw To cut any metallic thing

10. Outside calipers To measure outside dia

11. Inside calipers To measure inside dia

12. Slide calipers To measure very small dia

13. Vernier scale To measure very small dia

14. Chain ton To lift heavy load

15. Welding machine To join metallic parts

16. Grinding machine To make the smooth fabrics

17. Tester To test electric circuit

18. Pliers To grip anything & cut anything

19. Avometer/Voltmeter To measure voltage

20. Steel tape To measure length, width & height

21. Chisel To cut any metal

22. Gasket cutter For gasket cutting

23. File To smooth the rough surface

REMARKS:

The maintenance department of The Delta composite Knitting Ind Ltd is well equipped. It has sufficientmaintenance manpower including mechanical and electrical engineers. They do the maintenance of the m/csduring the Eid vacation. Otherwise, they do the breakdown maintenance. To increase the lifetime of themachineries and ensure the proper running of the machinery.

Page no: 52

UTILITY SERVICESCHAPTER - 8

Page no: 53

WATER TREATMENT PLANT:(Water Softening Method – Base Exchange Process)

TechnicalDetails

Raw water tank Softener tank Soft watertank

Brine tane

Size Length - 40´Width - 20´Height - 15´

Diameter – 6´Height - 15´

Diameter - 20´Height - 20´

Salt reqd:190kg/day/tankRegenerationtime 1.30 hr

Capacity 360 Ton 45 Cubicmeter/hour/tank

180 Ton

Source Natural sourceDeep tubewell

R.W.T S.T. Salt price10tk/kg

Project cost Total Project Cost : 113 Lacks

BOILER:Specifications:

1. Type : Fire Tube Boiler2. Brand Name : Cleaver Brooks, USA3. Type No. : DDH 15.0 – 104. Serial No. : 187095. Year of manufacturing : 19966. Max. Working pressure gauge : 10 bar7. Max Temperature : 1830 C8. Max heat capacity : 3.25 MW9. Water content up to ‘NW’ : 9.62 cubic meter10. Max steam out put : 5.0 ton/hr11. Gas pressure in line : 1 bar12. Gas pressure (in boiler) : 010 bar13. Gas consumption : 34 cubic meter/day14. Steam pressure : 7.5 bar15. Steam header pressure : 120 PSI16. Blow down line : 4 times/day17. Soft water supply pipe dia : 1 inch18. Establishment cost : 60 lacks

Page no: 54

ElectricityElectricity is supplied by: WAUKESHA (GAS GENERATOR)

Amp : 1565KVA : 1125KW : 900

CATER PILLAR (GAS GENERATOR)Amp : 702KVA : 487KW : 390

CAMINS (DIESEL GENERATOR)Amp : 139KVA : 100KW : 80

Electricity consumption – 50KW/day(A substation of voltage control – 1100 KV)

Utility cost:01. Gas bill (Titas) : 7-8 lacs / month02. Electricity Bill (REB) : 8-9 lacs / month03. Others : 5-6 lacs / month

Page no: 55

STORE & INVENTORY CONTROLCHAPTER - 9

Page no: 56

CHAPTER-IX

Store & Inventory ControlInventory system for Raw material:The Delta composite Knitting Ind Ltd. there are different inventory systems for different rawmaterials.Grey fabrics Store: All the grey fabrics arc stored in the fabric store, near the batch section.Different types of fabrics arc listed in the sheet according to the fabric types, quantity &consumer’s requirements. Fabrics GSM, shrinkage, diameter & other properties are also takeninto consideration. The batches are prepared by taking the required fabrics from the grey store.At present the grey fabrics store of The Delta composite Knitting Ind Ltd. containing thefollowing types of fabrics-

Single jersey 1 x 1 Rib 2 x 2 Rib 2 x 1 Rib Fleece Melange.. Pique Single jersey (with lycra attachment) 1 x 1 Rib (with lycra attachment)

Dyes & Chemicals Store:

There is a different time for dyes & chemicals_ Various types of dyes & chemicals arc storedhere according to the dyes & chemical company.Different types of dyes & chemicals are listed in a sheet. In the sheet the stored quantity of dyes& chemicals are also included. Everyday the sheet is updated & a copy of this sheet is suppliedto the AGM (production), Dye house & lab section.

Spares:

The Delta composite Knitting Ind Ltd. required amount of spares of different machines arestored in the mechanical store room. All the spares are listed in a sheet which is controlled by themechanical & maintenance personnel. Spares are arranged in the store room according to theresize, quantity & requirements. There are shelfs in the store room to keep the small spare parts.

Finished goods:The Delta composite Knitting Ind Ltd. supplies its finished dyed fabrics to its garments sectionSo. dyed finished fabrics are stored for short time in the finishing section. All the deliveredfabrics are noted on the tally khata according to the lot no, quantity, fabrics diameter, buyersname, color & considering other technical parameters.

Others:

There is a central store at the Ind Ltd. In that store the various types of forms, papers,stationary & other necessary goods are kept.

Page no: 57

Remarks:The Delta Composite Knitting Ind. Ltd. has individual stores for raw materials, finished goodsetc. the sotre of dyestuff & chemicals arc not so clean. There is no enough space to store thefinished goods. It requires to increase the store area.

Page no: 58

COST ANALYSISCHAPTER - 10

Page no: 59

COSTING OF THE PRODUCT

The following points are considered for costing any dyed product in The Delta Composite Knitting Ind.

Ltd.

1. Total dyes & chemical cost

2. Total utility cost

3. Salary

4. Payment

5. Transport cost

6. Lunch

7. Entertainment cost

8. Miscellaneous cost

9. Government cash incentive

Price of the product: Not available.

Costing of the product: Not available

REMARKS:The costing of the product is a secret matter of the Ind. They are not interested to flash up the

cost related data. So we could not collect the price of product & costing of the product.

Page no: 60

MARKETING ACTIVITIESCHAPTER - 11

Page no: 61

CONSUMERS OF PRODUCT:The Delta composite Knitting Ind. Ltd. is a 100% export oriented industry. All the goods produced inthis industry are exported into various foreign countries. Name of the main buyers are given below-

NAME OF THE BUYER:01.Tom Tailor02.H&M03.Echo Sourcing04.Well Lord05.Mono Prix

Importing countries:There are some countries which are importing goods from The Delta composite Knitting Ind. Ltd.The name of the countries are given below- Spain Germany Denmark Europe Denmark Europe Union United State of America

Manpower of marketing:Marketing plays a vital role in the field of displaying / showing the goods criteria of the products to thebuyer & to communicate with the buyer. There are about 15 people in the marketing section of theindustry.

Marketing Strategy:Marketing strategy is a very important factors to sale the products to the buyer. If the

marketing strategy is not so developed, it will be very hard to reach the goal. In case of garmentsmarketing the dealings with the buyer is a very important factor.

The Delta composite Knitting Ind. Ltd. mainly senior marketing officers, merchandiser &higher officials deal with the buyer. There are some fixed buyers of the industry. The buyers give theirorders continuously all over the year. The marketing officers & the merchandisers communicate withthe buying houses to collect the orders.

By both side understanding the rate & the order quantity are fixed.

Duties & responsibilities of marketing officer:Dealing with the buyer & convince the buyer is the main duty of marketing officer. A

marketing officer also has some other duties. The main duties & responsibilities of a marketing officerare given bellow- To prepare cost sheet by dealing with the buyer To take different steps by discussing with the high officials & merchandisers To maintain a regular & good relationship between commercial officer & merchandisers To maintain a communication with the buyers and buying houses Communicate with better criteria of the products

Page no: 62

Actually the responsibilities & duties of marketing officer begins from getting order of buyer &ends after receiving foods by the buyer. So, he should be always smart, energetic & sincere.

REMARKS:The Delta composite Knitting Ind Ltd. has a well learned marketing & merchandising team. Theyalways communicate with the buyers. The Delta composite Knitting Ind Ltd. has some fixedbuyers. The marketing section also looks the quality & quantity buyers.

Page no: 63

CONCLUSIONCHAPTER - 12

Page no: 64

The Delta Composite Knitting Industries Ltd. is a well-planned versatile project. Theadministrations, management, chain of command – all are well organized. They aredevoted to satisfy the customer by their activities. However, some of the point wewant to mention for the good of Delta Composite Knitting Industries Ltd. .

SOME SUGGESTIONS:- During the transport of the fabric in the dyeing floor and also during the

loading of the m/c, fabrics are soiled for the contact with floor. This makesthe fabric/part of the fabric dirty. It may require more scouring/bleachingagent or may create stain making it faulty.

- The dyeing floor is watery most of the time: it should be cleaned all thetime.

- The illumination of the dyeing shade should be enhanced. It may exert theworker fatigue ness.

- More skilled labour should be used in a project as Delta Composite KnittingIndustries Ltd.. Many time the dosing pipelines are clogged due to thecareless dosing of chemicals.

- The m/c stoppage time should be analyzed and minimized. Themaintenance should be carried out when the m/c is out of action(wherever possible)

Page no: 65

LIMITATIONS OF THE REPORT:- Because of secrecy act, the data on costing and marketing activities has

not been supplied & hence this report excludes these chapters.- We had a very limited time. In spite of our willing to study more details it was

not possible to do so.- Some of the points in different chapter are not described as these were not

available.- The whole process is not possible to bind in such a small frame as this report,

hence our effort spent on summarizing them.

LastlyWhat special in this report is that the information, data & description very much

subjective & practical. So, one can easily have an idea about the whole dyeing unitof Delta Composite Knitting Industries Ltd. at a single look on it.

The newcomer can use this report for further detailed study or can know DeltaComposite Knitting Industries Ltd. without much work. But what should beremembered the chemical, some process steps may be modified within the periodthis papers goes to the readers.